Hypertherm POWERMAX 45, Operator'S Manual

Page 1: ...45 Plasma arc cutting system Operator Manual 805780 Revision 2 ...

Page 2: ...________________________________ ____________________________________________________________________________ ____________________________________________________________________________ Maintenance notes ____________________________________________________________________________ ____________________________________________________________________________ _________________________________________...

Page 3: ...2 April 2013 Hypertherm Inc Hanover NH USA www hypertherm com Copyright 2013 Hypertherm Inc All Rights Reserved Hypertherm and powermax are trademarks of Hypertherm Inc and may be registered in the United States and or other countries 45 ...

Page 4: ...89 Tel 65 6841 2490 Fax 65 6841 2489 Technical Service Hypertherm Shanghai Trading Co Ltd Unit 301 South Building 495 ShangZhong Road Shanghai 200231 PR China 86 21 60740003 Tel 86 21 60740393 Fax Hypertherm Europe B V Vaartveld 9 4704 SE Roosendaal Nederland 31 165 596907 Tel 31 165 596901 Fax 31 165 596908 Tel Marketing 31 165 596900 Tel Technical Service 00 800 4973 7843 Tel Technical Service H...

Page 5: ...Safety information Before operating any Hypertherm equipment read the separate Safety and Compliance Manual 80669C included with your product for important safety information ...

Page 6: ......

Page 7: ...s 1 4 T45v torch dimensions 1 5 T45m torch dimensions 1 5 T45v and T45m torch specifications 1 6 Symbols and marks 1 7 IEC symbols 1 8 Section 2 Power Supply Setup Unpack the Powermax45 2 2 Claims 2 2 Contents 2 2 Position the power supply 2 3 Prepare the electrical power 2 3 Voltage configurations 2 3 Install a line disconnect switch 2 4 Requirements for grounding 2 4 Power cord considerations 2 ...

Page 8: ...t 3 25 Connect a machine interface cable 3 25 Accessing raw arc voltage 3 27 Connect the torch lead 3 28 Section 4 Operation Controls and indicators 4 2 Front controls and LEDs 4 2 Rear controls 4 3 Operate the Powermax45 4 3 Connect the electrical power and gas supply 4 3 Power ON the system 4 4 Set the mode switch 4 4 Adjust the gas pressure 4 4 Check the indicator LEDs 4 6 Attach the work clamp...

Page 9: ...tenance and Repair Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Repairs 5 6 Remove and replace the cover and Mylar barrier 5 6 Replace the work lead CSA and CE 5 7 Replace the gas filter element 5 8 Section 6 Parts Power supply parts 6 2 T45v hand torch parts 6 5 T45v hand torch consumables 6 6 T30v Powermax30 30 A consumables 6 6 T45m machine torch parts 6...

Page 10: ...Table of Contents iv powermax45 Operator Manual ...

Page 11: ...s electromagnetic disturbances must be reduced to the point where they are no longer troublesome Assessment of area Before installing the equipment the user shall make an assessment of potential electromagnetic problems in the surrounding area The following shall be taken into account a Other supply cables control cables signaling and telephone cables above below and adjacent to the cutting equipm...

Page 12: ... shock by touching these metallic components and the electrode nozzle for laser heads at the same time The operator should be insulated from all such bonded metallic components Earthing of the workpiece Where the workpiece is not bonded to earth for electrical safety nor connected to earth because of its size and position for example ship s hull or building steel work a connection bonding the work...

Page 13: ... This warranty shall not apply to any Powermax brand power supplies that have been used with phase converters In addition Hypertherm does not warranty systems that have been damaged as a result of poor power quality whether from phase converters or incoming line power This warranty shall not apply to any product which has been incorrectly installed modified or otherwise damaged Hypertherm provides...

Page 14: ...h damages National and local codes National and local codes governing plumbing and electrical installation shall take precedence over any instructions contained in this manual In no event shall Hypertherm be liable for injury to persons or property damage by reason of any code violation or poor work practices Liability cap In no event shall Hypertherm s liability if any whether such liability is b...

Page 15: ...System description 1 2 Where to find information 1 2 Power supply dimensions and weights 1 3 Dimensions 1 3 Weights 1 3 Power supply ratings 1 4 T45v torch dimensions 1 5 T45m torch dimensions 1 5 T45v and T45m torch specifications 1 6 Symbols and marks 1 7 IEC symbols 1 8 ...

Page 16: ...or See the Parts section for a list of spare and optional parts The power cords on the 200 240 V CSA power supplies are shipped with a 50 A 250 V plug NEMA 6 50P on the power cord The CE units and the 480 V CSA units are shipped without a plug on the power cord See Prepare the electrical power in the Power Supply Setup section for more information Where to find information System specifications su...

Page 17: ...low include the hand torch with 6 1 m 20 ft lead a 6 1 m 20 ft work lead and a 3 m 10 ft power cord CSA 200 240 V power supply 16 8 kg 37 pounds CSA 480 V power supply 15 9 kg 35 pounds CE 230 V power supply 16 6 kg 36 5 pounds CE 400 V power supply 15 9 kg 35 pounds 34 8 cm 13 7 in 31 cm 12 19 in 42 6 cm 16 75 in 17 2 cm 6 75 in ...

Page 18: ...t U2 MAX I2 MAX See Voltage configurations in the Power Supply Setup section for more information 200 240 VAC 34 28 A 200 240 CSA 230 VAC 30 A 230 V CE 400 VAC 10 A 400 V CE 480 VAC 8 5 A 480 V CSA Gas type Air Nitrogen Gas quality Clean dry oil free per ISO 8573 1 Class 1 2 2 99 995 pure Recommended gas inlet flow and pressure 170 l min at 6 2 bar 360 scfh at 90 psi Equipment complies with IEC 61...

Page 19: ...5 T45v torch dimensions T45m torch dimensions 22 1 cm 8 72 in 21 6 cm 8 5 in 8 3 cm 3 28 in 4 0 cm 1 58 in 2 5 cm 1 in 4 9 cm 1 91 in 36 5 cm 14 36 in 30 5 cm 12 in 2 5 cm 1 in 3 6 cm 1 43 in outer dimension 3 3 cm 1 3 in flat sides 33 0 cm 13 in ...

Page 20: ...es are the same as the handheld capacities 9 5 mm 3 8 in Recommended cut speed on mild steel 6 35 mm 1 4 in 1524 mm min 60 ipm 9 53 mm 3 8 in 813 mm min 32 ipm 12 7 mm 1 2 in 508 mm min 20 ipm 19 1 mm 3 4 in 203 mm min 8 ipm 25 4 mm 1 in 102 mm min 4 ipm Gouging capacity Metal removal rate on mild steel 2 8 kg hr 6 2 lbs hr Weight T45v torch only 0 27 kg 0 6 lb T45v with 6 1 m 20 ft lead 1 55 kg 3...

Page 21: ...he manufacturer s declaration of conformity to applicable European directives and standards Only those versions of Hypertherm products with a CE marking located on or near the data plate have been tested for compliance with the European Low Voltage Directive and the European Electromagnetic Compatibility EMC Directive EMC filters needed to comply with the European EMC Directive are incorporated wi...

Page 22: ...ate metal cutting Expanded metal cutting Gouging AC input power connection The terminal for the external protective earth conductor Gas test mode l Power is ON O Power is OFF f1 f2 1 An inverter based power source either 1 phase or 3 phase Volt amp curve drooping characteristic AC Power is ON LED System fault LED Inlet gas pressure fault LED Missing or loose consumables LED Power supply is out of ...

Page 23: ...tion the power supply 2 3 Prepare the electrical power 2 3 Voltage configurations 2 3 Install a line disconnect switch 2 4 Requirements for grounding 2 4 Power cord considerations 2 4 Extension cord recommendations 2 5 Generator recommendations 2 6 Prepare the gas supply 2 6 Connect the gas supply 2 7 Additional gas filtration 2 7 ...

Page 24: ... number located on the bottom of the power supply 3 Before you set up and operate this Hypertherm system read the Safety and Compliance Manual Claims Claims for damage during shipment If your unit was damaged during shipment you must file a claim with the carrier Hypertherm will furnish you with a copy of the bill of lading upon request If you need additional assistance call the nearest Hypertherm...

Page 25: ...urrents up to 10 times the rated value for short periods of time Voltage configurations The following chart shows the maximum rated output for typical combinations of input voltage and amperage Acceptable input voltages can be 10 of the values given below CAUTION Protect the circuit with appropriately sized time delay slow blow fuses and a line disconnect switch Model Input voltage Phase Rated out...

Page 26: ...nts for grounding To ensure personal safety proper operation and to reduce electromagnetic interference EMI the Powermax45 must be properly grounded The power supply must be grounded through the power cord according to national and local electrical codes Single phase service must be of the 3 wire type with a green or green yellow wire for the protective earth ground and must comply with national a...

Page 27: ...t voltage Phase 3 m 3 7 5 m 7 5 15 m 15 30 m 30 45 m 208 VAC 1 10 mm2 10 mm2 10 mm2 16 mm2 25 mm2 220 VAC 1 10 mm2 10 mm2 10 mm2 16 mm2 25 mm2 200 240 VAC 1 10 mm2 10 mm2 10 mm2 16 mm2 25 mm2 380 VAC 3 4 mm2 4 mm2 4 mm2 6 mm2 6 mm2 400 VAC 3 4 mm2 4 mm2 4 mm2 6 mm2 6 mm2 480 VAC 3 4 mm2 4 mm2 4 mm2 6 mm2 6 mm2 English Input voltage Phase 10 ft 10 25 ft 25 50 ft 50 100 ft 100 150 ft 208 VAC 1 8 AWG...

Page 28: ... OFF and then to ON again sometimes called a quick reset may not clear the fault Instead turn the power supply off and wait 30 to 45 seconds before turning it on again Prepare the gas supply The gas supply for the Powermax45 can be shop compressed or cylinder compressed A high pressure regulator must be used on either type of supply and must be capable of delivering gas to the filter on the power ...

Page 29: ...onditions introduce moisture oil or other contaminants into the gas line use a three stage coalescing filtration system such as the Eliminizer filter kit 128647 available from Hypertherm distributors A three stage filtering system works as shown below to clean contaminants from the gas supply The filtering system should be installed between the quick disconnect coupler and the power supply 5 5 6 9...

Page 30: ...Power supply setup 2 8 powermax45 Operator Manual ...

Page 31: ... consumables 3 3 Install the consumables 3 5 Machine torch setup 3 6 Mount the torch 3 6 Choose the consumables cut charts 3 8 Using the cut charts 3 8 T45m shielded consumables 3 8 Align the torch 3 24 Connect the remote start pendant 3 25 Connect a machine interface cable 3 25 Accessing raw arc voltage 3 27 Connect the torch lead 3 28 ...

Page 32: ... moisture or other contaminants Whether you are piercing the metal or starting cuts from the edge Proper torch to work distance when gouging or cutting with unshielded consumables Proper pierce height Which consumables you are using The T30v Powermax30 30 amp consumables will have a shorter life when used on the T45v However they provide optimum cut quality for certain applications Under normal co...

Page 33: ...sumables generally have a shorter life than shielded consumables however you may find that visibility and accessibility are better for some applications Consumables for hand cutting are shown below Notice that the retaining cap swirl ring and electrode are the same for shielded unshielded and gouging applications Only the shield deflector for unshielded consumables and the nozzle are different For...

Page 34: ...d consumables are not available for use in CE regulated countries T30v Powermax30 30 A consumables 220713 Retaining cap 220670 Swirl ring 220669 Electrode 220717 Deflector 220718 Nozzle 220483 Retaining cap 220480 Nozzle 220478 Electrode 220479 Swirl ring 220569 Optional deflector ...

Page 35: ... must have a complete set of consumable parts installed a shield or deflector retaining cap nozzle swirl ring and electrode With the power switch in the OFF O position verify that the torch consumables are installed as shown Retaining cap Nozzle Electrode Swirl ring Note Tighten only to finger tight Overtightening will cause the torch to misfire Shield or deflector There should be a small gap betw...

Page 36: ... the lead do so and then attach the torch to the lifter per the manufacturer s instructions Note The T45m can be mounted on a wide variety of X Y tables track burners pipe bevelers and other equipment Install the torch per the manufacturer s instructions and following the instructions below for disassembly if necessary If you need to disassemble the torch follow these steps 1 Disconnect the torch ...

Page 37: ...tting in the gas line when you route the lead through the track 6 Route the torch lead through the cutting table s track 7 Reattach the torch s power cable to the torch plunger using the screw and nut Rotate the plunger so that the screw does not interfere with the cap sensor switch 8 Reconnect the gas line to the torch lead 9 Press the two halves of the cap sensor switch s wire connector together...

Page 38: ...ollowing sections provide illustrations of the consumable sets and cut charts for each set Maximum cut speeds are the fastest speeds possible to cut material without regard to cut quality Recommended cut speeds are a good starting point for finding the best quality cut best angle least dross and best cut surface finish You will need to adjust the speeds for your application and your table to obtai...

Page 39: ...1 5 3 8 mm 250 0 0 9150 117 10160 118 0 8 8650 116 10160 117 0 9 8100 115 10160 117 1 5 0 2 5650 111 7100 115 45 0 9 1 5 3 8 mm 250 0 0 9652 115 10160 112 1 5 8890 116 10160 115 1 9 0 1 7100 117 9144 115 2 7 0 3 4800 117 6096 115 3 4 0 4 3550 117 4445 115 4 8 0 5 2150 118 2794 115 6 4 0 6 1500 120 1905 116 9 5 0 9 510 122 1016 116 12 7 Edge start recommended 510 132 635 125 15 9 280 138 356 127 19...

Page 40: ...400 117 0 036 in 20 Ga 320 115 400 117 0 060 in 16 Ga 0 2 225 111 280 115 45 0 036 in 20 Ga 0 06 0 15 in 250 0 0 380 115 400 112 0 060 in 16 Ga 350 116 400 115 0 075 in 14 Ga 0 1 280 117 360 115 0 105 in 12 Ga 0 3 190 117 240 115 0 135 in 10 Ga 0 4 140 117 175 115 0 188 in 3 16 in 0 5 85 118 110 115 0 250 in 1 4 in 0 6 60 120 75 116 0 375 in 3 8 in 0 9 32 122 40 116 0 500 in 1 2 in Edge start reco...

Page 41: ... mm min Voltage V 30 0 5 1 5 3 8 mm 250 0 0 9150 119 10160 123 0 8 8650 117 10160 121 0 9 8100 115 10160 119 1 5 0 2 3750 113 4700 118 45 0 9 1 5 3 8 mm 250 0 0 7600 112 10160 109 1 5 8100 112 10160 125 1 9 0 1 7100 118 9144 115 2 7 0 3 4050 118 5080 116 3 4 0 4 3050 121 3810 118 4 8 0 5 1780 122 2159 118 6 4 0 6 1100 124 1397 120 9 5 0 8 760 126 813 121 12 7 Edge start recommended 350 132 457 128...

Page 42: ... 400 123 0 030 in 22 Ga 340 116 400 121 0 036 in 20 Ga 320 115 400 119 0 060 in 16 Ga 0 2 145 111 185 118 45 0 036 in 20 Ga 0 06 0 15 in 250 0 0 300 115 400 109 0 060 in 16 Ga 320 116 400 125 0 075 in 14 Ga 0 1 280 117 360 115 0 105 in 12 Ga 0 3 160 117 200 116 0 135 in 10 Ga 0 4 120 117 150 118 0 188 in 3 16 in 0 5 70 118 85 118 0 250 in 1 4 in 0 6 44 120 55 120 0 375 in 3 8 in 0 8 30 122 32 121 ...

Page 43: ...in Voltage V Cut Speed mm min Voltage V 30 1 2 1 5 3 8 mm 250 0 0 9150 117 10160 120 1 5 0 2 8650 118 10160 121 1 9 5450 118 6860 121 45 1 5 1 5 3 8 mm 250 0 0 9150 116 10160 114 1 9 8650 117 10160 116 2 7 7100 120 9144 119 3 4 0 1 5600 122 7112 120 4 8 0 2 2550 123 3302 120 6 4 0 3 2050 123 2540 120 9 5 0 5 840 130 1067 125 12 7 Edge start recommended 510 134 635 130 19 1 200 143 254 138 Maximum ...

Page 44: ... 0 06 0 15 in 250 0 0 360 117 400 120 0 060 in 16 Ga 0 2 340 118 400 121 0 075 in 14 Ga 215 118 270 121 45 0 060 in 16 Ga 0 06 0 15 in 250 0 0 360 116 400 114 0 075 in 14 Ga 340 117 400 116 0 105 in 12 Ga 280 120 360 119 0 135 in 10 Ga 0 1 220 122 280 120 0 188 in 3 16 in 0 2 100 123 130 120 0 250 in 1 4 in 0 3 80 123 100 120 0 375 in 3 8 in 0 5 33 130 42 125 0 500 in 1 2 in Edge start recommended...

Page 45: ...in Voltage V Cut Speed mm min Voltage V 30 0 5 2 0 5 0 mm 250 0 0 9150 118 10160 114 0 8 8650 118 10160 116 0 9 8100 117 10160 120 1 5 0 2 5800 113 7250 119 45 0 9 2 0 5 0 mm 250 0 0 9650 118 10160 110 1 5 8900 114 10160 113 1 9 6100 114 7620 114 2 7 0 3 4450 116 5588 114 3 4 0 4 3400 118 4318 116 4 8 0 4 2150 118 2794 116 6 4 0 5 1500 118 1905 118 9 5 0 7 810 120 1016 118 12 7 Edge start recommen...

Page 46: ...18 400 116 0 036 in 20 Ga 320 117 400 120 0 060 in 16 Ga 0 2 225 113 285 119 45 0 036 in 20 Ga 0 08 0 2 in 250 0 0 380 118 400 110 0 060 in 16 Ga 350 114 400 113 0 075 in 14 Ga 240 114 300 114 0 105 in 12 Ga 0 3 175 116 220 114 0 135 in 10 Ga 0 4 135 118 170 116 0 188 in 3 16 in 0 4 85 118 110 116 0 250 in 1 4 in 0 5 60 118 75 118 0 375 in 3 8 in 0 7 32 120 40 118 0 500 in 1 2 in Edge start recomm...

Page 47: ...in Voltage V 30 0 5 2 0 5 0 mm 250 0 0 9144 113 10160 125 0 8 8128 115 10160 128 0 9 7000 114 9000 125 1 5 0 2 3650 112 4800 118 45 0 9 2 0 5 0 mm 250 0 0 8900 112 10160 110 1 5 8100 115 10160 113 1 9 0 1 7112 116 9144 114 2 7 0 3 4100 118 5080 116 3 4 0 4 2800 120 3556 118 4 8 0 5 1650 120 2032 118 6 4 0 6 1010 121 1270 118 9 5 0 8 610 125 762 120 12 7 Edge start recommended 355 130 457 126 19 1 ...

Page 48: ...3 400 125 0 030 in 22 Ga 400 115 400 128 0 036 in 20 Ga 345 114 345 125 0 060 in 16 Ga 0 2 145 112 180 118 45 0 036 in 20 Ga 0 08 0 2 in 250 0 0 350 112 400 110 0 060 in 16 Ga 320 115 400 113 0 075 in 14 Ga 0 1 280 116 360 114 0 105 in 12 Ga 0 3 160 118 200 116 0 135 in 10 Ga 0 4 110 120 140 118 0 188 in 3 16 in 0 5 64 120 80 118 0 250 in 1 4 in 0 6 40 121 50 118 0 375 in 3 8 in 0 8 24 125 30 120 ...

Page 49: ...n Voltage V Cut Speed mm min Voltage V 30 1 2 2 0 5 0 mm 250 0 0 8900 122 10160 121 1 5 0 1 8100 120 10160 118 1 9 0 2 5700 121 7100 119 45 1 5 2 0 5 0 mm 250 0 0 8900 120 10160 116 1 9 8100 120 10160 116 2 7 7200 122 9144 118 3 4 0 1 5500 123 6858 118 4 8 0 3 2540 123 3175 118 6 4 0 3 1820 128 2286 124 9 5 0 5 710 130 914 124 12 7 Edge start recommended 510 131 635 125 19 1 200 148 254 143 Maximu...

Page 50: ... 0 08 0 20 in 250 0 0 350 122 400 121 0 060 in 16 Ga 0 1 320 120 400 118 0 075 in 14 Ga 0 2 225 121 280 119 45 0 060 in 16 Ga 0 08 0 20 in 250 0 0 350 120 400 116 0 075 in 14 Ga 320 120 400 116 0 105 in 12 Ga 285 122 360 118 0 135 in 10 Ga 0 1 215 123 270 118 0 188 in 3 16 in 0 3 100 123 125 118 0 250 in 1 4 in 0 3 72 128 90 124 0 375 in 3 8 in 0 5 28 130 36 124 0 500 in 1 2 in Edge start recommen...

Page 51: ...mmended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec Cut Speed mm min Voltage V Cut Speed mm min Voltage V 30 0 5 0 5 2 5 mm 500 0 0 8900 105 10160 98 0 8 8100 102 10160 103 0 9 7100 101 8900 100 1 5 0 2 4450 97 5600 100 1 9 0 4 3050 98 3800 97 2 7 2050 96 2550 96 3 4 1270 100 1650 101 Maximum cut speed is limited by the test ...

Page 52: ... 97 220 100 0 075 14 Ga 0 4 120 98 150 97 0 105 12 Ga 80 96 100 96 0 135 10 Ga 50 100 65 101 T30v Powermax30 30 A consumables Air flowrate lpm Stainless steel Hot 131 2 Metric Cold 146 3 Recommended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec Cut Speed mm min Voltage V Cut Speed mm min Voltage V 30 0 5 0 5 2 5 mm 500 0 0 8900...

Page 53: ...380 98 0 060 16 Ga 0 2 150 99 190 98 0 075 14 Ga 0 4 110 101 135 97 0 105 12 Ga 60 101 75 98 0 135 10 Ga 45 102 55 97 T30v Powermax30 30 A consumables Air flowrate lpm Aluminum Hot 131 2 Metric Cold 146 3 Recommended Maximum Arc current amps Material thickness mm Torch to work distance mm Initial pierce height Pierce time delay sec Cut Speed mm min Voltage V Cut Speed mm min Voltage V 30 0 5 0 5 2...

Page 54: ...elay sec Cut Speed ipm Voltage V Cut Speed ipm Voltage V 30 0 036 20 Ga 0 02 0 10 in 500 0 0 320 107 400 105 0 060 16 Ga 240 104 300 103 0 075 14 Ga 190 104 240 103 0 105 12 Ga 0 2 145 103 180 103 0 135 10 Ga 95 101 120 101 Maximum cut speed is limited by the test table s maximum speed 400 ipm Align the torch Mount the machine torch perpendicular to the workpiece in order to get a vertical cut Use...

Page 55: ...des a maximum of 7 V under open circuit conditions This is an impedance protected functional extra low voltage ELV output to prevent shock energy and fire under normal conditions at the machine interface receptacle and under single fault conditions with the machine interface wiring The voltage divider is not fault tolerant and ELV outputs do not comply with safety extra low voltage SELV requiremen...

Page 56: ...b connector on the other end plug it into the appropriate pin connector on the torch height controller or CNC Secure it with the screws on the D sub connector If you are using a cable with wires and spade connectors on the other end terminate the machine interface cable inside the electrical enclosure of listed and certified torch height controllers or CNC controllers to prevent operator access to...

Page 57: ... VAC 1 A maximum at the machine interface relay or switching device supplied by the customer 12 14 Red black Ground Ground 13 Voltage divider Output Divided arc signal of 50 1 provides a maximum of 7 V 5 6 Black white Accessing raw arc voltage If you should need to access raw arc voltage contact your Hypertherm distributor or authorized Hypertherm repair facility for assistance WARNING High voltag...

Page 58: ...g and disconnecting the hand and machine torches When connecting or disconnecting a torch first power OFF the system To connect either torch push the connector into receptacle on the front of the power supply To remove the torch press the red button on the connector and pull the connector out of the receptacle Red button ...

Page 59: ...cator LEDs 4 6 Attach the work clamp 4 6 Understand duty cycle limitations 4 6 How to use the hand torch 4 7 Operate the safety trigger 4 7 Hand torch cutting hints 4 7 Start a cut from the edge of the workpiece 4 8 Pierce a workpiece 4 9 Gouge a workpiece 4 10 Common hand cutting faults 4 12 How to use the machine torch 4 12 Ensure the torch and table are set up correctly 4 12 Understand and opti...

Page 60: ...l cause one or more of the LEDs to blink For information on what these fault conditions are and how to correct them refer to the Basic troubleshooting topic in the Maintenance and Repair section AC Power ON LED green When illuminated this LED indicates that the power switch has been set to I ON and that the safety interlocks are satisfied Gas pressure LED and pressure bar yellow green When the LED...

Page 61: ...r grate top Non continuous pilot arc to cut metal plate middle Gouging bottom After you change the mode switch verify that the gas pressure is still set correctly Different modes of cutting require different pressure settings Rear controls 200 240 V CSA 230 V CE 400 V CE 480 V CSA I O I O ON I OFF O power switch Activates the power supply and its control circuits Operate the Powermax45 Follow the ...

Page 62: ... consumable life To cut metal plate middle position Use this setting to cut metal up to 25 4 mm 1 inch thick or pierce metal up to 12 7 mm 1 2 inch thick Gouging bottom position Use this setting to gouge metal Leaving the mode switch on this setting while cutting results in poor cut quality Adjust the gas pressure Look at the gas pressure LED If it illuminates green in the center of the pressure b...

Page 63: ... on top of the system to unlock it 3 Turn the pressure regulator knob until the gas pressure LED shows a green bar in the center of the pressure bar 4 Press down on the pressure regulator knob to lock it in position 5 Turn the amperage knob to the cutting current appropriate for your application If you are using T30v Powermax30 30 A consumables do not set the amperage knob above 30 A 45 30 40 40 2...

Page 64: ...sible to the area being cut Do not attach the work clamp to the portion of the workpiece to be cut away When the power ON LED is illuminated none of the other LEDs are illuminated or blinking the gas pressure LED indicates pressure is in the correct range the amperage knob is set and the work clamp is attached the system is ready for use Understand duty cycle limitations The duty cycle is the amou...

Page 65: ...e ready to cut with the torch flip the yellow safety trigger forward toward the torch head and press the red torch trigger as show below Hand torch cutting hints With shielded consumables drag the nozzle lightly along the workpiece to maintain a steady cut With unshielded consumables maintain an approximate 2 mm 0 08 inch distance between the tip of the torch and the workpiece This is between 1 6 ...

Page 66: ... circle cutting guide See the Parts section for part numbers for the Hypertherm plasma cutting guides for cutting circles and making bevel cuts Hold the torch nozzle perpendicular to the workpiece so that the nozzle is at a 90 angle to the cutting surface and watch the arc as it cuts along the line 1 With the work clamp attached to the workpiece hold the torch nozzle perpendicular 90 to the edge o...

Page 67: ...ING SPARKS AND HOT METAL CAN INJURE EYES AND BURN SKIN When firing the torch at an angle sparks and hot metal will spray out from the nozzle Point the torch away from yourself and others 1 With the work clamp attached to the workpiece hold the torch at an approximate 30 angle to the workpiece with the nozzle within 1 5 mm 1 16 inch of it before firing the torch 2 Fire the torch while still at an a...

Page 68: ... within 1 5 mm 1 16 inch from the workpiece before firing the torch 3 Hold the torch in place while continuing to press the trigger When sparks exit from the bottom of the workpiece the arc has pierced the material 4 When the pierce is complete drag the nozzle lightly along the workpiece to proceed with the cut 2 Hold the torch at a 45 angle to the workpiece with a small gap between the torch tip ...

Page 69: ... in 1 87 mm 0 0735 in 1016 mm min 40 ipm 5 30 mm 0 2087 in 1 31 mm 0 0517 in 1270 mm min 50 ipm 4 73 mm 0 1863 in 1 03 mm 0 0406 in 60 254 mm min 10 ipm 8 06 mm 0 3173 in 4 18 mm 0 1645 in 508 mm min 20 ipm 6 15 mm 0 2423 in 2 39 mm 0 0941 in 762 mm min 30 ipm 6 00 mm 0 2351 in 1 39 mm 0 0546 in 1016 mm min 40 ipm 5 80 mm 0 2281 in 1 21 mm 0 0476 in 1270 mm min 50 ipm 4 61 mm 0 1816 in 0 73 mm 0 0...

Page 70: ...g the torch too quickly or too slowly The arc sputters and consumables life is shorter than expected The cause can be Moisture in the gas supply The gas pressure is too low How to use the machine torch Since the Powermax45 and the T45m can be used with a wide variety of cutting tables track burners pipe bevelers and such you will need to refer to the manufacturer s instructions for specifics on op...

Page 71: ...e problem persists after mechanical causes have been eliminated see Ensure the torch and table are set up correctly on page 4 12 check the torch to work distance especially if the cut angles are all positive or all negative Also consider the material being cut If the metal is magnetized or hardened you are more likely to experience cut angle problems Dross Some amount of dross will always be prese...

Page 72: ...fect the straightness of the cut A strongly concave cut surface occurs when the torch to work distance is too low Increase the torch to work distance to straighten the cut surface A convex cut surface occurs when the torch to work distance is too great or the cutting current is too high First try lowering the torch then reduce the cutting current To pierce a workpiece using the machine torch As wi...

Page 73: ...cutting speed is not correct See the cut charts in the Torch Setup section for more information The amperage is set too low See the cut charts in the Torch Setup section for more information The consumables are worn and need to be changed The cut angle is not square Causes can be The direction of the torch travel is incorrect The high quality cut is always on the right with respect to the forward ...

Page 74: ...operation 4 16 powermax45 Operator Manual ...

Page 75: ...nce and Repair In this section Perform routine maintenance 5 2 Inspect the consumables 5 3 Basic troubleshooting 5 4 Repairs 5 6 Remove and replace the cover and Mylar barrier 5 6 Replace the work lead CSA and CE 5 7 Replace the gas filter element 5 8 ...

Page 76: ...hnician Every use Check the indicator lights and correct any fault conditions Inspect the consumables for proper installation and wear Every 3 months Replace any damaged labels Inspect the trigger for damage Inspect the torch body for cracks and exposed wires Replace any damaged parts Inspect the power cord and plug Replace if damaged Inspect the torch lead Replace if damaged Every 6 months or Cle...

Page 77: ...he electrode together Electrode The center surface for wear and verify the pit depth Replace if the surface is worn or the pit depth is greater than 1 6 mm 1 16 inch deep Replace the nozzle and the electrode together Swirl ring The internal surface for damage or wear and the gas holes for blockages Replace if the surface is damaged or worn or any of the gas holes are blocked Torch o ring The surfa...

Page 78: ...hen push it down to lock it Verify that the gas supply line is connected to the power supply and the gas is turned on Inspect the gas supply line for leaks and verify the incoming gas pressure The power ON LED is blinking The input line voltage is either too high or too low a variance greater than 15 of the rated voltage Have an electrical technician check the incoming power See the Specifications...

Page 79: ...bar s LED illuminates yellow at the bottom of the gauge and blinks Inlet gas supply pressure is lower than the minimum acceptable level The LED continues to blink for 10 seconds after the gas pressure is restored to the acceptable range The arc does not transfer to the workpiece Clean the area where the work clamp contacts the workpiece to ensure a good metal to metal connection Inspect the work c...

Page 80: ...onnect the power cord and disconnect the gas supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Gently pull on the end panel nearest the screw you are removing to keep pressure on the screw When the screw is almost out tilt the screwdriver slightly to help pull the screw out of the recessed hole 3 Tip the end panels back slightly so that you...

Page 81: ...that the bottom edges are in the tracks and that the slot in the top of the cover is aligned with the tab on the front end cap so that the louvers in the cover are in front of the fan Position the handle over the holes in the top of the cover then secure the cover with the 2 screws Three notches Cover slot Tab Four notches Replace the work lead CSA and CE 1 Turn OFF the power disconnect the power ...

Page 82: ...en secure the cover with the 2 screws 10 Reconnect the electrical power and the gas supply Replace the gas filter element 1 Turn OFF the power disconnect the power cord and disconnect the gas supply 2 Use a 2 Phillips screwdriver to remove the 2 screws from the handle on the top of the power supply Tip the end panels back slightly so that you can get the edges of the handle out from underneath the...

Page 83: ... drain onto the bottom of the filter bowl Reattach the hose if you removed it earlier 12 Reattach the filter bowl to the filter body making sure that the drain and drain hose point toward the front edge of the fan 13 Reposition the filter assembly in the bracket and replace its retainer nut 14 Reconnect the gas supply hose and press the drain hose onto the drain in the bottom of the power supply 1...

Page 84: ...Maintenance and Repair 5 10 powermax45 Operator Manual ...

Page 85: ...arts In this section Power supply parts 6 2 T45v hand torch parts 6 5 T45v hand torch consumables 6 6 T30v Powermax30 30 A consumables 6 6 T45m machine torch parts 6 7 T45m machine torch consumables 6 8 Accessory parts 6 8 Powermax45 labels 6 9 ...

Page 86: ... shown 3 228267 Kit Powermax45 handle and screws 4 228281 Kit Power supply cover with labels 200 240 V CSA 228283 Kit Power supply cover with labels CE 428076 Kit Power supply cover with labels Built in America 480 V CSA 5 228300 Kit Work lead assembly 6 1 m 20 ft 228307 Kit Work lead assembly 15 24 m 50 ft 228561 Kit Ground clamp not shown 6 108616 Current adjustment knob ...

Page 87: ...m 25 ft 023279 Machine interface cable start plasma arc transfer and ground 15 24 m 50 ft 123966 Powermax45 machine interface cable start plasma arc transfer 50 1 voltage divider and ground 7 62 m 25 ft spade connectors 123967 Powermax45 machine interface cable start plasma arc transfer 50 1 voltage divider and ground 15 24 m 50 ft spade connectors 223048 Machine interface cable start plasma arc t...

Page 88: ...PARTS 6 4 powermax45 Operator Manual 1 2 3 Item Part number Description 1 228287 Kit Filter regulator 2 228302 Kit Air filter element 3 228286 Kit Fan assembly ...

Page 89: ...5v hand torch assembly with 15 24 m 50 ft lead 1 228313 Kit T45v torch handle replacement 2 075714 T45v torch handle screws 4 x 1 2 SLTD Torx PAN S B 3 002244 Safety trigger and spring replacement 4 228346 Kit Torch head replacement 5 058503 O ring Viton 0 626 x 0 070 6 228109 Kit T45v torch cap sensor switch replacement 7 228315 Kit T45v torch lead replacement 6 1 m 20 ft 8 228316 Kit T45v torch ...

Page 90: ...d 220672 Nozzle Unshielded 220717 Deflector 220718 Nozzle The swirl ring retaining cap and electrode for these applications are the same as those for the shielded application Unshielded consumables for the hand torch are not available in CE regulated countries T30v Powermax30 30 A consumables Part number Description 220569 Deflector 220483 Retaining cap 220480 Nozzle 220479 Swirl ring 220478 Elect...

Page 91: ...228228 Kit T45m positioning sleeve 2 228229 Kit T45m removable gear rack 3 228322 Kit T45m front mounting ring 4 228323 Kit T45m rear mounting ring 5 228320 Kit T45m torch head replacement 6 228321 Kit T45m cap sensor switch replacement 7 058503 O ring Viton 0 626 x 0 070 8 228317 Kit T45m torch lead replacement 7 62 m 25 ft 9 228318 Kit T45m torch lead replacement 10 67 m 35 ft 10 228319 Kit T45m...

Page 92: ... parts Part number Description 024548 Brown leather torch sheathing 7 5 m 25 ft 024877 Black leather torch sheathing 7 5 m 25 ft 128658 Gouging heat shield 127102 Basic plasma circle cutting guide 027668 Deluxe plasma circle cutting guide 127219 Powermax45 dust cover 127217 Powermax45 shoulder strap 128647 Kit Eliminizer air filtration 127103 Face shield shade 8 lens 127239 Face shield shade 6 len...

Page 93: ...t shade of filter 7 do not remove destroy or cover this label Replace if it is missing damaged or worn Plasma cutting can be injurious to operator and persons in the work area Consult manual before operating Failure to follow all these safety instructions can result in death PN 110673 Rev D AVeRTISSeMeNT Le coupage plasma peut être préjudiciable pour l opérateur et les personnes qui se trouvent su...